Mold forming compactor with selectively variable hydraulic pressure means

ABSTRACT

A mold-forming compactor for compressing and packing a molding material such as sand within a flask containing a pattern to a preselected mold hardness wherein a frame is provided to support a compactor roll and an endless loop conveyor which continually passes beneath the compactor roll provided on its periphery with spaced boss members for purposes of compaction. Means are provided to synchronize the timed correlation of the rotary velocity of the compacting roll and the lineal velocity of the conveyor so that these velocities are equal causing the loose mold-forming material deposited in the flask to be compacted by the engaging boss member therein around the pattern. Hydraulic means is provided to support the compacting roll as well as apply compacting pressure thereto to selectively vary the mold hardness of the molding material within the flask.

United States Patent [72] Inventor John Staley 281 Franklin Drive,Pittsburgh, Pa. 15241 [211 App]. No. 35,017 [22] Filed May 6, 1970 [45]Patented Dec. 21,1971

[54] MOLD FORMING COMPACTOR WITH SELECTIVELY VARIABLE HYDRAULlC PRESSUREMEANS 6 Claims, 7 Drawing Figs.

[52] U.S. Cl 164/208, 25/99 [51] Int. Cl ..B22c 15/08, B28b 5/02 [50]Field of Search 164/208, 210, 40, 207; 25/99 [561 References CitedUNlTED STATES PATENTS 690.716 1/1902 Fletcher 25/99 X PrimaryExaminer-Robert D. Baldwin Attorney-Carothers 81. Carothers ABSTRACT: Amoldforming compactor for compressing and packing a molding materialsuch as sand within a flask containing a pattern to a preselected moldhardness wherein a frame is provided to support a compactor roll and anendless loop conveyor which continually passes beneath the compactorroll provided on its periphery with spaced boss members for purposes ofcompaction. Means are provided to synchronize the timed correlation ofthe rotary velocity of the compacting roll and the lineal velocity ofthe conveyor so that these velocities are equal causing the loosemold-forming material deposited in the flask to be compacted by theengaging boss member therein around the pattern. Hydraulic means isprovided to support the compacting roll as well as apply compactingpressure thereto to selectively vary the mold hard ness of the moldingmaterial within the flask.

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FIGBQ INVENTOF? MOLD FORMING COMPACTOR WITH SELECTIVELY VARIABLEHYDRAULIC PRESSURE MEANS This invention relates to a novel and usefulrolling sand mold compactor which can be utilized to compress theforming mold material such as sand around the object pattern, and ofdesired sand mold hardness by means of roll compacting action. Sand moldas used herein constitutes all material and in gredients and otherforming materials used in forming molds forthe purposes ofproducingcastings.

The machine of the instant invention is constructed in a manner so as tobe readily manufactured from readily available material secured fromstock warehouse material, motors, controls and components. Additionally,the machine construction of the instant invention, is adaptable tomolding requirements of a wide variety of production demands, withreduced maintenance due to the continuous smooth function of the movingparts. All motion of the machine is uniform and in one direction.Additionally, the rolling sand mold compactor is capable of providingthe desired level of mold hardness through automatically controlledpressure cylinders.

An object ofthis instant invention is to provide a sand mold- 'mg devicewhich can automatically produce sand molds of desirable mold hardness ona continuous basis.

An additional object of the invention is to automatically providesatisfactory sand molds in a minimum of time.

Another object is to eliminate the necessity of the complex equipmentrequired now for automatically forming sand molds.

These and other objects with their advantages which will becomesubsequently apparent from the details of construction and operation ofthe compactor as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings forming a part hereof, whereinlike numerals refer to like parts throughout, and in which:

FIG. 1 is a side elevation of the rolling sand mold compactor with thepattern conveyor comprising this invention.

FIG. 2 is an end elevation of the rolling sand mold compactor andpattern conveyor.

FIG. 3 is a plan view of the rolling sand mold compactor of FIG. 1.

FIG. 4 is an enlarged side view of the pressure regulating device forthe compactor roll.

FIG. 5 is an enlarged plan view of the pressure regulating guides.

FIG. 6a is a side view of the roll and a boss member.

FIG. 6b is an end view of the roll and boss members.

Referring now more specifically to the drawings the numeral 11 generallydesignates the rolling sand mold compactor.

From FIGS. 1 and 2 of the drawings it will be seen that the constructionof the mold forming compactor 11 comprises two roll support stands 12with a roll 20 supported between the stands. Attached to the surface ofthe roll 20 is a raised boss member 13 which is fastened by means ofbolts 1. Between the stands 12 and under the roll are two rails 14 ofthe loop conveyor 16 to convey the patterns 15 and flask 27 and sandmaterial. From FIG. 1, it can be seen that the pattern conveyor 16 isconstructed in a closed elongated loop. The patterns 15 are attached tothe loop conveyor 16 and serve as the pressure bed ofthe roll compactor11.

FIG. 4 shows the roll support block 17 with the automatic pressurehydraulic-adjusting cylinders 18. The drive 19 for the roll compactor l1and the pattern conveyor 16 is driven by motor 2 and the output drives 3and 4 for the roll 20 and the conveyor 16, respectively, aresynchronized at selected speeds to simultaneously deliver a pattern 15to the roll 20 with the boss member 13 in a bottom position to engageand compact the mold sand material deposited in the flask 27.

The roll stands 12 comprise a rectangular frame made up of structuralrectangular members 21 and 22 and are connected by a cross member 23 atthe top. Connected to slidably engage members 21 are roll support guidemeans in the form of two guides 24 and accompanying support blocks 17for vertical adjustment of the compactor roll 20 by means of thecylinders 18. There is identical cylinders 18 and support guide means onopposite sides of the roll 20 to support the same. The stands 12 areconnected by cross members 23 at the top and cross members 25 at thebottom. Between the roll stands 12 at a low elevation are conveyor rails14 which. support and deliver and guide the pattern 15 and accompanyingflask 27 to the compactor roll 20.

The pattern loop conveyor 16 is a chain-connected type driven by asynchronized sprocket 26 linked to the roll drive 19. The loop conveyor16 moves continually with the patterns 15 passing beneath conveyor frame5 and then proceeding around the end of frame 5 to be positioned forreceiving a flask 27 and molding material, as indicated in FIG. 1, forsubsequent compacting.

The pressure regulating cylinder raises and lowers the compactor rolland boss member by means of guides 24 and hydraulic pressure. Increasedhydraulic pressure supplied to cylinders 18 from pressure line 6 lowersthe roll and boss member into compacting position to compact moretightly the molding material.

FIG. 6 shows the construction of the roll 20 and the boss members 13with bolted fasteners l. The boss members 13 can be removed, changed orreplaced as determined by requirements of the pattern. Negative patternboss members can be used to develop satisfactory mold hardness on deepdraw patterns.

Mold hardness can also be adjusted by a strike off bar 29 which can beadjusted vertically to remove excess forming material prior tocompacting.

OPERATION For purposes ofillustration, it may be assumed that thepattern 15 is in its normal upright position on conveyor 16 movingtoward the compactor roll 20. As it assumes upright position at 28 aflask 27, synchronized for position, is inserted over pattern centeringpins (not shown) forming a mold unit ready to receive molding materialfrom an overhead molding material conveyor. The mold material conveyoror hopper will fill the flask 27 with a predetermined amount of materialas the unit advances to the mold compactor at a uniform rate ofmovement. As the unit advances to synchronous compactor roll 20, strikeoff bar 29 removes any excess mold material to a preselected height. Themold unit advances to the compactor roll 20 and the boss members 13 at auniform and continuous synchronous angular velocity will be equal to thelinear velocity of the conveyor 16. The leading edge of the flask 27passes under the roll 20 approximately one-quarter of an inch ahead ofthe leading edge of the boss member 13. As the boss member rotates andthe flask unit advances with the boss member, the latter of whichcompresses and compacts the molding material around the pattern 15 to aselect and desired hardness as determined by (A).depth and pressure ofthe boss member and (B) amount of material remaining after passing underthe strike off bar 29 prior to reaching the compactor roll 20. Thetrailing edge of the boss member 13 exits the mold void of the flask 27approximately one-quarter inch ahead of the trailing edge of the flask.

The boss member dimensions are such as to allow at least onequarter inchedge clearance around the interior flask void to insure uniformcompaction and mold hardness and no engagement of the boss member 13with the sides and edges of the flask 27.

Upon exiting from the compactor roll area the flask-pattern unit isseparated at a draw station by removal of the flask and mold unit fromthe pattern carrying frame and the pattern 15 recycles via the loopconveyor 16. The process of continuous mold forming on a production linebasis is obtained with the rate of mold production determined by varyingthe drive 19.

SUMMARY In review, the mold-forming compactor comprising my invention isdesigned for compressing and packing a molding material such as moldingsand within a flask containing a pattern to a preselected mold hardnesswherein the flask and mold units are presented to the compactor roll ina continuous manner through the provision of a loop conveyor while atthe same time the compactor roll is supported by hydraulic means whichis oflered to selectively vary the desired resultant mold hardness ofthe molding material placed within the flask prior to compacting. Themold-forming compactor structure comprises upright structural membersand cross members connected together to support a roll and boss memberfor compacting mold-forming material around a pattern present within theflask by means of the rolling action of the compactor roll. Theprinciple of my invention is based on the fact that the boss member ofthe roll applies pressure to the molding material along a horizontalplane across the face of the moving boss member, that is, parallel tothe axis of the compactor roll, and the molding material is compacted asthe same moves under the approaching boss member. Maximum compaction isachieved at the lowest diameter point of the periphery of the bossmember as the molding material passes therebeneath, this being thelowest point of the boss member of the compactor roll when in engagementwith the molding material within the flask and mold unit.

Means are provided on the compactor to adjust the compactor rollperipheral speed or velocity with the lineal velocity of the patterncarrying frame connected to form a loop conveyor. Compacting pressure isregulated by means of a hydraulic cylinder positioned on adjacent sidesof the compacting roll by varying the hydraulic pressure to thehydraulic cylinders through operation of the provided pressure controlregulators and associated hydraulic pump and motor mechanism.

The boss members may be of any selected number as attached to the maincompactor roll suspended between the structural frame members andthereby positioned at various radial points along the rollcircumference. Also, various sizes of compactor rolls and boss membersmay be employed to match and correspond with the flask andpattern-carrying frames to be utilized with the mold-forming compactor.

Thus, it can be seen that the mold-forming compactor comprising thisinvention incorporates a pattern movement along the loop conveyor from apoint where there is joined together the flask and the pattern-carryingframe through the moldmaking process to a point where the flask and moldunit are removed from the pattern-carrying frame with the entire methodbeing repeated through the use of the loop conveyor.

Also, it will be noted that by means of using the fasteners l and othersuch fastening devices, it is readily easy to provide for fastchangeability from one type of boss member to another. Also, the bossmember patterns may be varied in geometric configurations for attachmentto the compactor roll for producing desired mold hardness and of moldingmaterial onto patterns requiring compacting in specific areas relativeto the shape of the particular pattern being employed. For example,multiple-footed boss members can be supplied for attachment to thecompactor roll to produce desired mold conditions.

Roll support guide means are provided in the form of the guide 24 andthe support-bearing block 17 to contain and support the compactor rolland the boss members in correct vertical position over the loop conveyorand passing pattern-carrying frame so that the compactor roll may beraised and lowered to apply the boss members in consecutive fashion tothe molding material deposited within the flask to achieve the desiredmold hardness.

Guide rails and other mechanisms may be provided to maintain thepattern-carrying frames and flask in proper aligned position relative tothe engagement by the boss members of the compactor roll. Also, avariable height strike off bar indicated at 29 may be utilized to levelthe molding material prior to the compaction process.

I claim: l. A mold-forming compactor for compressing and packing amolding material within a flask containing a pattern to a preselectedmold hardness comprising a frame for rotatably supporting a compactorroll, spaced boss members on the cylindrical surface of said roll, aloop conveyor adapted for continuous passage under said roll andincluding a series of pattern-carrying frames, synchronized positionmeans to apply a mold flask on each of said frames and molding materialconveyor means to fill each flask prior to passage of saidpatterncarrying frames and applied mold flasks under said roll,synchronizing means connected to and driven by motor means for timedcorrelation of the rotational velocity of said boss members relative tothe lineal passage of said applied flask and pattern-carrying frames sothat the arcuate surfaces of said boss members are caused to compact themolding material within said flask, hydraulic means operative on saidroll to apply compacting pressure to said boss members when compactingthe molding material within said flasks and hydraulic regulating meansto vary the pressure application of said hydraulic means to selectivelyvary the mold hardness of the molding material within the flask.

2. The mold forming-compactor of claim characterized by a draw stationto withdraw said flask with compacted and molded material therein fromsaid pattern-carrying frames after passage under said compactor roll.

3. The mold-forming compactor of claim 1 characterized by a strike offbar secured to said roll frame forward of said compactor roll andadjustably positioned for height relative to said applied flasks tolevel the molding material prior to compacting by said roll.

4. The mold-forming compactor of claim 1 characterized by conveyor railsto guide consecutively each of said applied flask and pattern-carryingframes under said roll in aligned relation relative to said bossmembers.

5. The mold-forming compactor of claim 1 characterized by verticalstands comprising a portion of said roll frame, a vertical slot in saidstands to slidably receive roll support guide means, said hydraulicmeans secured to said roll support guide means to support andselectively vary the vertical height of said compactor roll relative tosaid pattern-carrying frames.

6. The mold-forming compactor of claim 1 characterized in that said bossmembers are releasably attached to said roll to permit various sizes ofboss members to be attached to said roll corresponding to the size ofsaid mold flasks.

1. A mold-forming compactor for compressing and packing a moldingmaterial within a flask containing a pattern to a preselected moldhardness comprising a frame for rotatably supporting a compactor roll,spaced boss members on the cylindrical surface of said roll, a loopconveyor adapted for continuous passage under said roll and including aseries of pattern-carrying frames, synchronized position means to applya mold flask on each of said frames and molding material conveyor meansto fill each flask prior to passage of said patterncarrying frames andapplied mold flasks under said roll, synchronizing means connected toand driven by motor means for timed correlation of the rotationalvelocity of said boss members relative to the lineal passage of saidapplied flask and patterncarrying frames so that the arcuate surfaces ofsaid boss members are caused to compact the molding material within saidflask, hydraulic means operative on said roll to apply compactingpressure to said boss members when compacting the molding materialwithin said flasks and hydraulic regulating means to vary the pressureapplication of said hydraulic means to selectively vary the moldhardness of the molding material within the flask.
 2. The moldforming-compactor of claim characterized by a draw station to withdrawsaid flask with compacted and molded material therein from saidpattern-carrying frames after passage under said compactor roll.
 3. Themold-forming compactor of claim 1 characterized by a strike off barsecured to said roll frame forward of said compactor roll and adjustablypositioned for height relative to said applied flasks to level themolding material prior to compacting by said roll.
 4. The mold-formingcompactor of claim 1 characterized by conveyor rails to guideconsecutively each of said applied flask and pattern-carrying framesunder said roll in aligned relation relative to said boss members. 5.The mold-forming compactor of claim 1 characterized by vertical standscomprising a portion of said roll frame, a vertical slot in said standsto slidably receive roll support guide means, said hydraulic meanssecured to said roll support guide means to support and selectively varythe vertical height of said compactor roll relative to saidpattern-carrying frames.
 6. The mold-forming compactor of claim 1characterized in that said boss members are releasably attached to saidroll to permit various sizes of boss members to be attached to said rollcorresponding to the size of said mold flasks.